Method of making a transaction instrument

ABSTRACT

A transaction instrument and a method of making a transaction instrument by continuous liquid interface production. The transaction instrument such as a transaction card may have many features or components made by or using continuous liquid interface production.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.14/933,472, filed Nov. 5, 2015, which is a continuation-in-part of U.S.application Ser. No. 14/564,842, filed on Dec. 9, 2014, which claimspriority from U.S. Provisional Application No. 61/914,118, filed Dec.10, 2013, the contents of each of which are incorporated herein byreference.

FIELD OF THE INVENTION

The present invention relates to a method of making a transactioninstrument such as for use in a financial transaction.

BACKGROUND OF THE INVENTION

Payment cards are used every day for financial transactions throughoutthe world. The most common examples of payment cards are credit cardsand debit cards. The most common method by which such cards arecurrently mass manufactured is by extruding and/or calendaring one ormore layers of plastic, applying printing, and laminating said layers,often along with additional foils or protective coatings. However, thereare disadvantages associated with such processes. Mass manufacturingcreates the card and then subsequently the card must be personalizedthrough embossing, printing, laser etching or some other means. A recessmay have to be formed through milling or another removal process inorder to allow for the insertion of the devices such as a packagecontaining an integrated circuit and contacts. Mass manufacturing alsodoes not support customization of shape, color, or other features of thecard body on a card by card basis. Mass manufacturing is not well suitedto producing metal cards, since they are expensive and difficult topersonalize. Mass manufacturing does not support production in remotelocations such as a branch location or a customer site. Also, massmanufacturing is done in larger batches and creates inventory andcarrying costs. There are also disadvantages associated with othermanufacturing methods such as 3D printing methods which are slow formanufacturing purposes and produce rough-sided objects.

Thus, there is a need for an alternative method of making a payment cardor transaction instrument that addresses the disadvantages.

SUMMARY OF THE INVENTION

The present invention relates to a transaction instrument and a methodof making a transaction instrument by a method comprising continuousliquid interface production, also referred to as “CLIP.”

In an embodiment of the present invention, a method of making atransaction instrument is provided. The method comprises providing apool of liquid photopolymer resin and producing a transaction instrumentby continuous liquid interface production.

In another embodiment of the present invention, a method of making atransaction instrument comprises making an object from a digital modelby continuous liquid interface production, and the object is a financialtransaction instrument.

In yet another embodiment of the present invention, a kit is provided.The kit comprises a transaction instrument made by continuous liquidinterface production. The transaction instrument has one or morerecesses formed in the transaction instrument, and at least one of amachine readable indicium, integrated circuit, antenna, or a combinationthereof, each configured for insertion into one of the one or morerecesses.

Further areas of applicability of the present invention will becomeapparent from the detailed description provided hereinafter. It shouldbe understood that the detailed description and specific examples, whileindicating the preferred embodiment of the invention, are intended forpurposes of illustration only and are not intended to limit the scope ofthe invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from thedetailed description and the accompanying drawings, which are notnecessarily to scale, wherein:

FIG. 1 illustrates a transaction instrument made by a method comprisingcontinuous liquid interface production into a form of a transactioncard.

FIG. 2 illustrates a transaction instrument made by a method comprisingcontinuous liquid interface production into a form of a watch blank.

FIG. 3 illustrates a transaction instrument made by a method comprisingcontinuous liquid interface production into a form of a ring.

FIG. 4 illustrates the top view of a transaction instrument as made by amethod comprising continuous liquid interface production into a form ofa transaction card that has a recess on the top face to allow theinsertion of a device into the top surface.

FIG. 5 illustrates a top view of a transaction instrument as made by amethod comprising continuous liquid interface production into the formof a card that has a recess on the bottom surface below imaginary dashedlines to allow the insertion of a device into the bottom surface.

FIG. 6 illustrates a top view of a card or portion thereof as made by amethod comprising continuous liquid interface production with a recessto allow for the insertion of contactless antenna and chip.

FIG. 7 illustrates a top view of a card as made by a method comprisingcontinuous liquid interface production showing a contactless antenna andassociated chip package directly under the imaginary dashed lines whichwas covered over by continuous liquid interface production.

FIG. 8 illustrates a top view of a card as made by a method comprisingcontinuous liquid interface production with a recess such as forinsertion of a magnetic strip.

FIG. 9 illustrates a top view of a card as made by a method comprisingcontinuous liquid interface production showing an outline above therecess on the bottom for insertion of a magnetic strip.

FIG. 10A illustrates a card showing recesses for inlaid decoration.

FIG. 10B illustrates a card with inlaid decoration added.

FIG. 11 illustrates a transaction card having a contactless antenna inwhich the antenna was made as part of a method comprising continuousliquid interface production.

FIG. 12 illustrates a recess for an inset device such as an EMV chip.

FIG. 13 illustrates a transaction card having contact pads such as EMVcontact pads.

FIG. 14 illustrates a typical package for a contact smart card.

FIG. 15 illustrates a transaction card having a hole made for a keychain or other

FIGS. 16A and 16B illustrate that decorative holes in a transaction cardof various patterns or shapes.

FIG. 17 illustrates a transaction card made by a method comprisingcontinuous liquid interface production having a textured finish.

FIG. 18 illustrates a transaction card made by a method comprisingcontinuous liquid interface production having texture combined withholes.

FIG. 19 illustrates a transaction card made by a method comprisingcontinuous liquid interface production having contours includingthree-dimensional images.

FIG. 20 illustrates a transaction card made by a method comprisingcontinuous liquid interface production having beveled or filleted cardedges.

FIG. 21 illustrates a transaction card having a metal or non-metal foillayer(s).

FIG. 22 illustrates a transaction card having an ultraviolet (UV) and/orscratch resistant layer(s).

FIG. 23 illustrates a transaction card having a colored or picturelayer(s) or areas.

FIG. 24 illustrates a transaction card having a transparent layer(s) orareas.

FIG. 25 illustrates a transaction card with personalization.

FIG. 26 illustrates that the lettering may be added by personalizationwith continuous liquid interface production in accordance with themethod of the present invention.

FIG. 27 illustrates a station of a personalization line identified as acontinuous liquid interface production station for personalization.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description of the embodiment(s) is merelyexemplary in nature and is in no way intended to limit the invention,its application, or uses.

The present invention relates to a transaction instrument made by amethod comprising continuous liquid interface production, also referredto as “CLIP.” Continuous liquid interface production generally refers toa process that uses a pool of liquid photopolymer resin to form asmooth-sided solid object. At the bottom of the pool, there is a portionof the pool or a window that allows oxygen as well as ultraviolet (UV)light pass through it. Since oxygen blocks curing of the resin, thewindow forms a dead zone of non-curable resin on the bottom of the pool.The UV light beam illuminates the cross-section of an object and thelight causes the resin to solidify. Thus, the UV light passes throughthe window and cures any low-oxygen resin sitting right above the deadzone. The object being manufactured is drawn upward from the liquid. Inan embodiment of the present invention, a transaction instrument is madeusing such process.

In accordance with the invention, the transaction instrument is enabledto perform a financial transaction and is suitable for use in afinancial transaction such as making a purchase or conducting anothertype of monetary transaction in commerce. Transaction instruments may bein the form of cards such as a credit card, debit card, automatic-tellermachine (ATM) card, check card, stored-value cards, and gift cards,among others. Transaction instruments may be associated with varioustypes of financial accounts such as a credit card account, debit cardaccount, automatic-teller machine (ATM) account, direct deposit account,check, closed loop gift card account, open loop gift card account, or acombination thereof. Transaction instruments may take other variousforms including, but not limited to, various electronic devices. Asindicated above, the transaction instrument formed by continuous liquidinterface production may be in various shapes and sizes. For example,the transaction instrument may be made by continuous liquid interfaceproduction into a traditional credit or debit card as shown in FIG. 1.The transaction instrument may be made by continuous liquid interfaceproduction into an electronic device in a form of a watch as shown inFIG. 2. The transaction instrument may be made by continuous liquidinterface production into an electronic device in a form of a braceletor a ring as shown in FIG. 3. The transaction instrument may be made bycontinuous liquid interface production into an electronic device in aform of a key ring or key fob, among other forms.

In an aspect of the invention, the transaction instrument is a card thathas at least two sides or surfaces. The transaction card may have agraphics layer on one or both sides having an indicium indicative of anaccount associated with the transaction card. The indicium can beprovided by at least one personalization process. The personalizationprocess may comprise at least one of dye sublimation printing, screenprinting, gravure printing, lithography, inkjet printing, laserprinting, indentation, continuous liquid interface production, or acombination thereof. As a feature of the invention, the indicium isprovided free from milling or laser etching. The indicium can also beprovided by continuous liquid interface production. The indicium can beof a different color than the side of the card. The indicium can beraised with respect to the side of the card. The indicium may compriseBraille lettering.

In another aspect of the invention, the card is enabled to perform afinancial transaction by inclusion of a machine readable indicium. Themachine readable indicium may comprise a magnetic strip. As a feature ofthe invention, the transaction card comprises a recess to accommodatethe machine readable indicium. The recess may begin approximately 3.8 mm(0.15 inches) to 16.5 mm (0.65 inches) from the longer edge of the cardand have a width ranging from approximately 2.54 mm (0.10 inches) to10.1 mm (0.40 inches). The recess can be made by leaving a void duringthe continuous liquid interface production process. The recess can bemade using subtractive manufacturing after continuous liquid interfaceproduction. In another feature of the invention, continuous liquidinterface production inclusive of the recess is done onto or around themachine readable indicium.

The transaction card has a surface finish m a range of 0.15 micrometers(6 microinches) to 0.40 micrometers (15.9 microinches).

In another aspect of the invention, the transaction card is compliantwith at least a portion of ISO 7810, ISO 7811, ISO 7816, or acombination thereof.

The method of making the transaction instrument of the present inventioncomprises continuous liquid interface production. Continuous liquidinterface production generally refers to making an object or shape froma digital computer model. A transaction instrument made in accordancewith the present invention is comprised of material formed in a devicedirected by a computer model.

Among the types of continuous liquid interface production processes thatmay be suitable for use in the method of the present invention include,but are not limited to, stereolithography above an oxygen permeablewindow, involving photopolymerization of resins. Additionally,continuous liquid interface production of metals and metal blendprocesses may be suitable for use in the method of the presentinvention.

As indicated above, the transaction instrument made by continuous liquidinterface production may be made in various shapes and sizes. Thetransaction instrument may also be finished. The transaction instrumentmay be finished, for example, by subtractive manufacturing.

A transaction instrument may be created by continuous liquid interfaceproduction into a transaction card such as a credit card or debit cardas illustrated in FIG. 1. As shown in FIG. 1, a platform or tablecomprising one or more transaction cards can be built by continuousliquid interface production. A transaction instrument may be created bycontinuous liquid interface production into an electronic device inanother form. As shown in FIG. 2, a table comprising one or more watchblanks can be built by continuous liquid interface production. Atransaction instrument may be created by continuous liquid interfaceproduction into an electronic device in another form such as a braceletor a ring as shown in FIG. 3. As shown in FIG. 3, a table comprising oneor more ring blanks can be built by continuous liquid interfaceproduction. The transaction instrument may be created by continuousliquid interface production into an electronic device into a formincluding, but not limited to, a key ring or key fob, ring, watch, wristband, bracelet, card, and other shaped devices.

The materials used in the transaction instrument of the presentinvention and in the method comprising continuous liquid interfaceproduction include, but are not limited to, plastic, metal, ceramic,carbon, graphite, diamond nanocrystals, and a combination thereof. Theterm “metal”, as used herein, includes, but is not limited to, metallicelements, metal-containing compounds, other metal forms, or acombination thereof. The plastic may further comprise a plasticizer. Theplastic may be optically transparent. The optically transparent plasticmay be opaque to some or all light outside of the visible spectrum. Theoptically transparent plastic may be opaque to ultraviolet light.

In a preferred aspect of the invention, a combination of materials usedis a plastic and metal blend such as a metal-filled plastic ormetal-filled polymer.

Examples of materials that may be suitable for a method comprisingcontinuous liquid interface production include, but are not limited to,trimethylolpropane triacrylate using a photoinitiator,diphenyl(2,4,6-trimethyl-benzoyl)phosphine oxide, and reactive diluentssuch as n-vinylpyrrolidone, isobornyl acrylate, and cyclohexanedimethanol di-vinyl ether. Photoinitiators include, but are not limitedto, phenylbis(2,4,6-trimethyl-benzoyl)phosphine oxide,1-hydroxycyclohexyl phenyl ketone, and2-benzyl-2-(dimethylamino)-4′-morpholinobutyrophenone (reference #1).Plastics include, but are not limited to, polyvinyl chloride (PVC),polyvinyl chloride acetate (PVCA), oriented polyester, polyethylene,polyethylene terephthalate including biaxially-oriented polyethyleneterephthalate, polyethylene glycol (PET-G), acrylonitrile butadienestyrene (ABS), polycarbonate, polypropylene, and a combination thereof.

In accordance with aspects of the present invention, the method ofmaking a transaction instrument comprises making an object of any shapefrom a digital computer model. The method comprises providing a pool ofliquid photopolymer resin, lifting a shape from a pool of liquid whilesolidifying material as the shape emerges from the liquid pool. In anaspect of the invention, the shape is in the form of a transactioninstrument.

The method of making a transaction instrument in accordance with thepresent invention may comprise modeling, continuous liquid interfaceproduction steps, and finishing.

As to modeling, the method comprises virtual blueprints taken fromcomputer aided design (CAD) or animation modeling software into acontinuous sequence of UV images generated by a digital light processingimaging unit. The computer software may comprise a feature forcustomization of a shape for the transaction instrument, customizationof personalization for the transaction instrument, or a combinationthereof.

A standard data interface between CAD software and the machines is thestereolithography (STL) file format. An STL file approximates the shapeof a part or assembly using triangular facets. Smaller facets produce ahigher quality surface. Polygon file format (PLY) is a scanner generatedinput file format, and virtual reality modeling language (VRML or WRL)files could be used as input for continuous liquid interface productiontechnologies that are in full color.

As to finishing, the method may further comprise making throughcontinuous liquid interface production a slightly oversized version ofthe object in standard resolution and then removing material with ahigher-resolution subtractive process.

The method may further comprise continuous liquid interface productionto pre-form a recess(es) around one or more components or inset devicesof the transaction instrument. As a feature of the invention, the insetdevice is optionally set in a pocket or a pouch, and continuous liquidinterface production inclusive of the recess is done onto or around thepocket or the pouch. In order to protect the device from the liquid, thematerial could be deposited forming a void around the inset device orthe inset device set in the pocket or the pouch. Examples of one or morecomponents include, but are not limited to, a chip such as aEuropay-Mastercard-Visa (EMV) chip, a contactless antenna, a contactlessantenna chip, a magnetic strip, an in-laid decoration, embeddedfeatures, and continuous liquid interface production created features.The recess has a size and a shape to accommodate the component or insetdevice with or without the pocket or the pouch.

In an aspect of the present invention, the inset device comprises atleast one integrated circuit, also referred to as a chip. FIG. 4illustrates the top view as made by a method comprising continuousliquid interface production of a transaction instrument in a form of atransaction card that has a recess on the top face to allow theinsertion of a device into the top surface. The front of the card showsa recess such as for insertion of a chip. A recess is generally definedas an indentation, a cavity or an opening. The recess is left as a voidwhen the card is produced. The recess may be filled with supportive,non-binding material or may simply be an empty space.

FIG. 5 illustrates a top view as made by a method comprising continuousliquid interface production of a transaction instrument in the form of acard that has a recess on the bottom surface below the imaginary dashedlines to allow the insertion of a device into the bottom surface. Therecess is on the downward facing front of the card. In thisconfiguration, the recess may be filled with supportive, non-bindingmaterial or with a pre-made blank that is either a part of the buildplatform or is placed on top of the build platform.

In accordance with aspects of the method of the present invention, themethod comprises forming the card around the chip. In order to protectthe chip from the liquid, the material could be deposited forming a voidaround the chip.

In an aspect of the invention, transaction card may have a recess for acontactless antenna/wires and a contactless antenna chip. This featureis particularly desirable for a split layer card where the recess is onan inner layer and the recessed portion would have the wires and chipadded and then laminated to the other layers.

FIG. 6 illustrates the top view of a card or portion thereof as made bya method comprising continuous liquid interface production with a recessto allow for the insertion of contactless antenna and chip. The recessis on the downward facing front of the card. In this case, the recess isfilled with supportive, non-binding material or with a pre-made blankthat is either a part of the build platform or is placed on top of thebuild platform.

FIG. 7 illustrates a top view of a card as made by a method comprisingcontinuous liquid interface production showing a contactless antenna andassociated chip package directly under the imaginary dashed lines wherethe card was created around the package.

FIG. 8 illustrates another possible feature of a transaction card. FIG.8 illustrates a top view of a card as made by a method comprisingcontinuous liquid interface production with a recess such as forinsertion of a magnetic strip. A magnetic strip is another possiblefeature of a transaction card made in accordance with the presentinvention. The recess may be filled with supportive, non-bindingmaterial or may simply be empty space.

FIG. 9 illustrates a top view of the card as created by continuousliquid interface production showing an outline above the recess on thebottom for insertion of a magnetic strip. The recess is on the downwardfacing front of the card. In this case, the recess can be filled withsupportive, non-binding material or with a pre-made blank that is eithera part of the build platform or is placed on top of the build platform.

In accordance with aspects of continuous liquid interface production thetransaction instrument of the present invention, there may be decorativefeatures to a transaction card. One such example is an inlaid decorationas illustrated in FIGS. 10A and 10B. The transaction instrument may becreated around the inlay by creating it around the inlay as it is liftedfrom the liquid.

FIG. 10A illustrates a card showing recesses for inlaid decoration, andFIG. 10B illustrates a card with inlaid decoration added. In accordancewith the method comprising continuous liquid interface production of thepresent invention, a recess or recesses may or may not be created whenthe card is created. Depending on the type of continuous liquidinterface production technology, the recess may be filled withsupportive, non-binding material or may simply be empty space. Therecess may be filled with supportive, non-binding material or with apre-made blank that is either a part of the build platform or is placedon top of the build platform. Inlaid decoration(s) are laid down firstand then card is built on top of it.

In accordance with aspects of making a transaction instrument of thepresent invention, the transaction instrument may be made by a methodcomprising continuous liquid interface production with embedded,fabricated features. The transaction instrument may be made of one ormore types of materials. For example, a metal antenna may be madethrough a method comprising continuous liquid interface production and aplastic card body may be made around or over it through a methodcomprising continuous liquid interface production.

A transaction instrument may be made by a method comprising continuousliquid interface production to have various features including, but notlimited to, the following features. FIG. 11 illustrates a transactioncard having a contactless antenna in which the antenna was made as partof a method comprising continuous liquid interface production process. Aplastic card body may be made by a method comprising continuous liquidinterface production with a metal antenna (shown in black) also made bya method comprising continuous liquid interface production. Analternative is the plastic body can be made by another method ofmanufacture, inserted onto the build platform, and then the antenna canbe made through a method comprising continuous liquid interfaceproduction. Completion of the plastic card can then be done by a methodcomprising continuous liquid interface production or traditionallamination of layers.

FIG. 12 illustrates a recess for an inset device such as an EMV chip.

In another aspect of the present invention, the inset device comprisesone or more conducting contact pads. FIG. 13 illustrates a transactioncard having conducting contact pads such as EMV contact pads. Thecontact pads can be made in any shape as long as the required contactpoints are included. In another feature of the present invention, thecontact pad(s) are located as set forth in ISO 7816 and/or havedimensions including a minimum size as set forth in ISO 7816.

The plastic card body may be made through a method comprising continuousliquid interface production or traditional methods of making a plasticcard body. For example, a chip such as an EMV chip and/or a lead packageis placed in a card body or a card body is built around the chip and thelead package. A contact pad for an EMV chip is made in metal through amethod comprising continuous liquid interface production. The shape ofthe created contacts can be decorative and take any shape as long as thefive required contact pads are covered. FIG. 14 illustrates a typicalpackage for a contact smart card and card body, noting that a smart cardhas conductive contact pads (metal contacts). The conductive pads areattached to a chip by small bond wires. The conductive pad, chip, andbond wires are pre-manufactured into a package. This package has a depthof up to 20 mils and is deeper in the center than on the edges. Thepackage is inserted and secured typically with a chip adhesive and a hotmelt glue into a recess with a deep center of approximately 20 mils anda shallower perimeter of 5 mils to 7 mils. The active chip side inrelation to the substrate and encapsulation is illustrated in FIG. 14.

Another feature of a transaction card made in accordance with the methodof the present invention is a hole made for a keychain or otherattachment as shown in FIG. 15. An attachment hole may be at anylocation on the card that does not have other required elements such asthe magnetic stripe, chip, signature area, embossing area, among otherelements. Decorative holes may be made in various patterns or shapes asshown in FIGS. 16A and 16B. A decorative hole or holes may be made atany location on the card that does not have other required elements suchas the magnetic stripe, chip, signature area, embossing area, amongother elements.

A transaction card made by a method comprising continuous liquidinterface production in accordance with the present invention may have atextured finish as illustrated in FIG. 17. FIG. 17 illustrates a cardhaving a dimpled texture; however, many textures are possible such as ina pattern (such as shown), randomly, or in a way that makes a picture.Texture can also be combined with holes as shown in FIG. 18.

A transaction card made by a method comprising continuous liquidinterface production in accordance with the present invention may havecontours, including 3D images as illustrated in FIG. 19. The faceillustrated in FIG. 19 is an example of making a picture using contours.The use of contours can also be combined with different colors.

A transaction card made by a method comprising continuous liquidinterface production in accordance with the present invention may havebeveled or filleted card edges as illustrated in FIG. 20. There are avariety of treatments that could be applied to the card edge.

A transaction card made by a method comprising continuous liquidinterface production in accordance with the present invention maycomprise layers of different types of materials. For example, FIG. 21illustrates a transaction card having a metal or non-metal foillayer(s). FIG. 22 illustrates a transaction card having an ultraviolet(UV) and/or scratch resistant layer(s). FIG. 23 illustrates atransaction card having a colored or picture layer(s) or areas. Coloredareas may include logos or other images, for example. FIG. 24illustrates a transaction card having a transparent layer(s) or areas.As shown in FIG. 24, the transparent area of area(s) show color frombehind.

Another aspect of a transaction instrument, including a transactioncard, made by a method comprising continuous liquid interface productionin accordance with the present invention is personalization. Part ofpersonalization relates to fabrication. Fabrication is considered aspart of making the body of the card through continuous liquid interfaceproduction. FIG. 25 illustrates a card with personalization. FIG. 26illustrates that the lettering may be added by personalization inaccordance with the method of the present invention. Created graphicsmay also be added.

As an additional step in a method comprising continuous liquid interfaceproduction, in either of the two examples below, the completed cardwould subsequently be personalized (lettering in black) typically at thetime the card was needed for a particular customer. For a card made by amethod comprising continuous liquid interface production, the card orset of cards on a sheet made through continuous liquid interfaceproduction would be reloaded into a continuous liquid interfaceproduction machine for personalization.

For a card made by other methods such as traditional layers, a card orset of cards on a sheet made through traditional lamination would beloaded to a continuous liquid interface production machine forpersonalization.

The present invention encompasses various ways in which to differentiatepersonalization from background including, but are not limited to,recessed, raised and a different shade or color. With recessed, thepersonalization would be at a lower elevation than the surface of thecard. With raised, the personalization would be at a higher elevationthan the surface of the card. With a different color or shade, thepersonalization would be a color and/or shade designed to differentiateit from the surface of the card. Color differentiation could be combinedwith either recessed or raised lettering/numbering. Examples ofpersonalized elements include, but are not limited to, name, accountnumber, expiration date, card verification number, braille, andorientation.

For the visually impaired, braille could be used as an optionalindication of the card's identity, bank name, and acceptance brand(Visa, MasterCard, Discover, American Express). The braille could be ofa different height.

With regard to orientation, text could be parallel to the long axis ofthe card, “horizontal” or text could be parallel to the shorter axis ofthe card, “vertical” or text could be a combination of horizontal andvertical. The transaction card or instrument itself could be made to behorizontal or vertical in orientation.

A transaction instrument made by a method comprising continuous liquidinterface production can be manufactured at a remote location such as aretail store, bank branch, office, or a residence that has compatiblecontinuous liquid interface production capability.

Remote manufacturing using a method comprising continuous liquidinterface production could be accomplished under the control of the bankor other issuing institution at a remote location. This allows directinteraction with the customer for input into the customization and moreexpedient pickup or delivery.

Remote manufacturing using a method comprising continuous liquidinterface production could also be accomplished under direct control ofthe end user by allowing the end user to download the requiredspecification and files as well as acquire any non-continuous liquidinterface production-made components required to produce the transactioninstrument. A machine readable indicium and other non-continuous liquidinterface production-made card components can be made available in a kitat the remote location for inclusion in a recess of the transactioncard. The machine readable indicium can be made directly onto thetransaction card inclusive of the recesses for continuous liquidinterface production-made components.

Remote manufacturing using a method comprising continuous liquidinterface production could also be accomplished by a distributor such asa retail store. In this instance, the store could produce one or a widevariety of transaction instrument types without the need to keepinventory of multiple transaction instrument types such as gift cardsspecific to a range of retailers. In another aspect of the presentinvention, a transaction card personalization line is provided. Thetransaction card personalization line comprises a continuous liquidinterface production station for personalization of transaction cards.FIG. 27 illustrates a station of a personalization line identified as acontinuous liquid interface production station for personalization.Examples of personalization include, but are not limited to, an indiciumindicative of an account associated with the transaction card, a name ofan individual or a company associated with the transaction card, Braillelettering, or a combination thereof. In another feature, the indicium israised with respect to a surface of the transaction card. In still yetanother feature, the indicium is of a different color than the surfaceof the card. Other stations may include, but are not limited to,magnetic strip and smart card encoding, laser engraving, color printing,graphics printing, basic topcoat and card guard UV-curing topcoat,embossing/topping, label affixing, and a combination thereof.

It will therefore be readily understood by those persons skilled in theart that the present invention is susceptible of broad utility andapplication. Many embodiments and adaptations of the present inventionother than those herein described, as well as many variations,modifications and equivalent arrangements, will be apparent from orreasonably suggested by the present invention and the foregoingdescription thereof, without departing from the substance or scope ofthe present invention. Accordingly, while the present invention has beendescribed herein in detail in relation to its preferred embodiment, itis to be understood that this disclosure is only illustrative andexemplary of the present invention and is made merely for purposes ofproviding a full and enabling disclosure of the invention. The foregoingdisclosure is not intended or to be construed to limit the presentinvention or otherwise to exclude any such other embodiments,adaptations, variations, modifications and equivalent arrangements.

What is claimed is:
 1. A method of making a transaction instrument, themethod comprising: generating, based on a virtual blueprint of thetransaction instrument, a sequence of ultraviolet (UV) images; andproducing the transaction instrument by continuous liquid interfaceproduction based on the sequence of UV images, wherein producing thetransaction instrument comprises, for each UV image in the sequence ofUV images: curing a portion of a pool of liquid photopolymer resin toform a different feature of the transaction instrument based on the UVimage; and drawing the transaction instrument upward from the pool ofthe liquid photopolymer resin.
 2. The method of claim 1, whereingenerating the sequence of UV images comprises converting the virtualblueprint of the transaction instrument from computer modeling softwareinto the sequence of UV images to be produced by a digital lightprocessing imaging unit.
 3. The method of claim 1, further comprisinggenerating the virtual blueprint of the transaction instrument usingcomputer modeling software that includes a feature for at least one ofcustomization of a shape for the transaction instrument or customizationof personalization for the transaction instrument.
 4. The method ofclaim 1, wherein producing the transaction instrument comprises: curinga first portion of the liquid photopolymer resin to form a body of thetransaction instrument based on a first UV image of the sequence of UVimages; drawing the transaction instrument upward from the pool of theliquid photopolymer resin; curing a second portion of the liquidphotopolymer resin to form a texture on the body of the transactioninstrument based on a second UV image of the sequence of UV images; anddrawing the textured transaction instrument upward from the pool of theliquid photopolymer resin.
 5. The method of claim 1, wherein producingthe transaction instrument comprises: curing a first portion of theliquid photopolymer resin to form a body of the transaction instrumentbased on a first UV image of the sequence of UV images; drawing thetransaction instrument upward from the pool of the liquid photopolymerresin; curing a second portion of the liquid photopolymer resin to formone or more contours on the body of the transaction instrument based ona second UV image of the sequence of UV images, wherein the one or morecontours create a picture on the body of the transaction instrument; anddrawing the contoured transaction instrument upward from the pool of theliquid photopolymer resin.
 6. The method of claim 1, wherein producingthe transaction instrument comprises: curing a first portion of theliquid photopolymer resin to form a body of the transaction instrumentbased on a first UV image of the sequence of UV images; drawing thetransaction instrument upward from the pool of the liquid photopolymerresin; curing a second portion of the liquid photopolymer resin to formpersonalized lettering on the body of the transaction instrument basedon a second UV image of the sequence of UV images; and drawing thepersonalized transaction instrument upward from the pool of the liquidphotopolymer resin.
 7. The method of claim 1, wherein producing thetransaction instrument comprises: curing a first portion of the liquidphotopolymer resin to form a first layer of the transaction instrumentincluding a recess based on a first UV image of the sequence of UVimages, wherein the recess is configured to receive a contactlessantenna; drawing the first layer of the transaction instrument upwardfrom the pool of the liquid photopolymer resin; curing a second portionof the liquid photopolymer resin to form a second layer of thetransaction instrument based on a second UV image of the sequence of UVimages, wherein the second layer is formed over the first layer and thecontactless antenna within the recess; and drawing the transactioninstrument upward from the pool of the liquid photopolymer resin.
 8. Themethod of claim 1, wherein producing the transaction instrumentcomprises: curing a first portion of the liquid photopolymer resin toform a first layer of the transaction instrument including a recessbased on a first UV image of the sequence of UV images, wherein therecess is configured to receive an inset device; drawing the first layerof the transaction instrument upward from the pool of the liquidphotopolymer resin; curing a second portion of the liquid photopolymerresin to form a second layer of the transaction instrument based on asecond UV image of the sequence of UV images, wherein the second layeris formed over the first layer and around the inset device within therecess; and drawing the transaction instrument upward from the pool ofthe liquid photopolymer resin.
 9. The method of claim 8, wherein theinset device comprises one or more of conducting contact pads, a leadpackage, an EMV chip, or a magnetic strip.
 10. The method of claim 1,wherein producing the transaction instrument comprises: curing a firstportion of the liquid photopolymer resin to form a first layer of thetransaction instrument based on a first UV image of the sequence of UVimages; drawing the first layer of the transaction instrument upwardfrom the pool of the liquid photopolymer resin; curing a second portionof the liquid photopolymer resin to form a second layer of thetransaction instrument based on a second UV image of the sequence of UVimages, wherein the second layer is a protective layer formed over thefirst layer; and drawing the transaction instrument upward from the poolof the liquid photopolymer resin.
 11. A system comprising: a computingdevice configured to generate a sequence of ultraviolet (UV) imagesbased on a virtual blueprint of a transaction instrument; and acontinuous liquid interface production (CLIP) station in communicationwith the computing device and including a pool of liquid photopolymerresin, the CLIP station configured to produce the transaction instrumentby continuous liquid interface production based on the sequence of UVimages, wherein, to produce the transaction instrument, the CLIP stationis configured to, for each UV image in the sequence of UV images: cure aportion of the liquid photopolymer resin to form a different feature ofthe transaction instrument based on the UV image, and draw thetransaction instrument upward from the pool of the liquid photopolymerresin.
 12. The system of claim 11, wherein the CLIP station includes adigital light processing imaging unit, and wherein, to generate thesequence of UV images, the computing device is configured to convert thevirtual blueprint of the transaction instrument from computer modelingsoftware executed on the computing device into the sequence of UV imagesto be produced by the digital light processing imaging unit.
 13. Thesystem of claim 11, wherein the computing device is configured toexecute computer modeling software used to generate the virtualblueprint of the transaction instrument, wherein the computer modelingsoftware includes a feature for at least one of customization of a shapefor the transaction instrument or customization of personalization forthe transaction instrument.
 14. The system of claim 11, wherein, toproduce the transaction instrument, the CLIP station is configured to:cure a first portion of the liquid photopolymer resin to form a body ofthe transaction instrument based on a first UV image of the sequence ofUV images; draw the transaction instrument upward from the pool of theliquid photopolymer resin; cure a second portion of the liquidphotopolymer resin to form a texture on the body of the transactioninstrument based on a second UV image of the sequence of UV images; anddraw the textured transaction instrument upward from the pool of theliquid photopolymer resin.
 15. The system of claim 11, wherein, toproduce the transaction instrument, the CLIP station is configured to:cure a first portion of the liquid photopolymer resin to form a body ofthe transaction instrument based on a first UV image of the sequence ofUV images; draw the transaction instrument upward from the pool of theliquid photopolymer resin; cure a second portion of the liquidphotopolymer resin to form one or more contours on the body of thetransaction instrument based on a second UV image of the sequence of UVimages, wherein the one or more contours create a picture on the body ofthe transaction instrument; and draw the contoured transactioninstrument upward from the pool of the liquid photopolymer resin. 16.The system of claim 11, wherein, to produce the transaction instrument,the CLIP station is configured to: cure a first portion of the liquidphotopolymer resin to form a body of the transaction instrument based ona first UV image of the sequence of UV images; draw the transactioninstrument upward from the pool of the liquid photopolymer resin; cure asecond portion of the liquid photopolymer resin to form personalizedlettering on the body of the transaction instrument based on a second UVimage of the sequence of UV images; and draw the personalizedtransaction instrument upward from the pool of the liquid photopolymerresin.
 17. The system of claim 11, wherein, to produce the transactioninstrument, the CLIP station is configured to: cure a first portion ofthe liquid photopolymer resin to form a first layer of the transactioninstrument including a recess based on a first UV image of the sequenceof UV images, wherein the recess is configured to receive a contactlessantenna; draw the first layer of the transaction instrument upward fromthe pool of the liquid photopolymer resin; cure a second portion of theliquid photopolymer resin to form a second layer of the transactioninstrument based on a second UV image of the sequence of UV images,wherein the second layer is formed over the first layer and thecontactless antenna within the recess; and draw the transactioninstrument upward from the pool of the liquid photopolymer resin. 18.The system of claim 11, wherein, to produce the transaction instrument,the CLIP station is configured to: cure a first portion of the liquidphotopolymer resin to form a first layer of the transaction instrumentincluding a recess based on a first UV image of the sequence of UVimages, wherein the recess is configured to receive an inset device;draw the first layer of the transaction instrument upward from the poolof the liquid photopolymer resin; cure a second portion of the liquidphotopolymer resin to form a second layer of the transaction instrumentbased on a second UV image of the sequence of UV images, wherein thesecond layer is formed over the first layer and around the inset devicewithin the recess; and draw the transaction instrument upward from thepool of the liquid photopolymer resin.
 19. The system of claim 18,wherein the inset device comprises one or more of conducting contactpads, a lead package, an EMV chip, or a magnetic strip.
 20. The systemof claim 11, wherein, to produce the transaction instrument, the CLIPstation is configured to: cure a first portion of the liquidphotopolymer resin to form a first layer of the transaction instrumentbased on a first UV image of the sequence of UV images; draw the firstlayer of the transaction instrument upward from the pool of the liquidphotopolymer resin; cure a second portion of the liquid photopolymerresin to form a second layer of the transaction instrument based on asecond UV image of the sequence of UV images, wherein the second layeris a protective layer formed over the first layer; and draw thetransaction instrument upward from the pool of the liquid photopolymerresin.